Ornamental molding and method of manufacture

ABSTRACT

An ornamental molding and method of manufacture have a positive molding ( 1 ) made of solidified foam material coated with predetermined cementitious-like material having a selected ornamental shape and predetermined resistivity to natural destructiveness. A negative molding ( 6 ) in which the positive molding is formed also is made preferably from solidified foam material that is coated with a release agent. The solidified foam material is preferred for its light weight, ease of forming and low cost. Additional advantages of the solidified foam material are long life with coating protection for the positive mold and contrastingly easy destruction and discard of the negative mold after being used to make the positive molding. For a wide selection of ornamental moldings, the positive and the negative moldings can be formed together by parting them from a single piece of solidified foam material with a cutting instrument ( 8 ) that can include a hot wire, a hot rod, a fluid jet stream or a laser beam. For moldings having compound curvature of interfaces, the positive and the negative moldings can be made from different pieces of solidified foam material that are shaped separately. Designs may be imprinted on the ornamental molding by attaching a layer of material, such as silicone rubber, bearing a design before injecting the cementitious-like material between the positive and negative molds.

BACKGROUND OF THE INVENTION

[0001] This invention relates to ornamental molding and its method ofmanufacture in foam forms with decorative cementitious-like materialsfor buildings, monuments, pillars, gateways, walls, graves and otherstructures.

[0002] Natural stone and fabricated stone are heavy and difficult to cutor customize for decorative moldings. When formed, their weight makesthem difficult to put in place for ornamental decoration. There is noknown lightweight ornamental molding alternative that is strong,durable, inexpensive and controllably decorative in a manner taught bythis invention.

[0003] Examples of most-closely related known but different devices aredescribed in the following patent documents: U.S. Pat. No. InventorIssue Date 5,766,728 Iwaya Jun. 16, 1998 6,054,080 Sheahan, et al. Apr.25, 2000 4,010,232 Labrecque Mar. 01, 1977 3,856,257 Wetstone Dec. 24,1974 5,076,928 Blum Dec. 31, 1991 6,060,006 Savenok May 09, 20004,067,164 McMillan Jan. 10, 1978 5,672,391 Santarossa Sep. 30, 19975,819,485 Lane, et al. Oct. 13, 1998

SUMMARY OF THE INVENTION

[0004] Objects of patentable novelty and utility taught by thisinvention are to provide ornamental molding which:

[0005] is quick and easy to make;

[0006] can be customized readily for a wide selection of structuralornamentation;

[0007] is lightweight for ease of handling while being made and whilebeing put into ornamental position;

[0008] can be glued to surfaces reliably when made;

[0009] is rodent, bird and pest resistant;

[0010] has widely variable textural, color and surface designingpotential; and

[0011] is long lasting.

[0012] This invention accomplishes these and other objectives with anornamental molding and method of manufacture having a positiveornamental molding made of solidified foam material coated withpredetermined cementitious-like material having a selected ornamentalstructure and predetermined resistivity to natural destructiveness. Anegative molding in which the positive molding is formed also is madepreferably from solidified foam material that is coated with a releaseagent. The solidified foam material is preferred for its light weight,ease of forming and low cost. Additional advantages of the solidifiedfoam material are long life with coating protection for the positivemold and contrastingly easy destruction and discard of the negativemold. For a wide selection of ornamental moldings having straight-lineinterfaces, the positive and the negative moldings can be formedtogether by parting them from a single piece of foamed material with ahot rod, a fluid jet stream or a laser beam. For molding compoundcurvature of interfaces, the positive and the negative moldings can bemade from different pieces of foamed material that are shapedseparately. Designs may be imparted to the cementitious-like material byattaching to the negative mold a layer of material, preferably aresilient material such as silicone rubber, bearing a design. The term“cementitious-like” is defined herein to include any material that isliquid in the initial use phase and then cures to a hardened state likecement, including, without limitation, such materials as gypsum, cement,natural stone aggregate, polymer, plaster of paris, cultured marble orany mixture of these materials.

[0013] The above and other objects, features and advantages of thepresent invention should become even more readily apparent to thoseskilled in the art upon a reading of the following detailed descriptionin conjunction with the drawings wherein there is shown and describedillustrative embodiments of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0014] This invention is described by appended claims in relation todescription of a preferred embodiment with reference to the followingdrawings which are explained briefly as follows:

[0015]FIG. 1 is a perspective view of a piece of solidified foammaterial being cut into a positive molding and a negative molding with acutting instrument that can include a hot wire, a resistance-heated rodor a laser jet;

[0016]FIG. 2 is a side elevation view of the positive molding positionedin the negative molding with a gap between them for receivingcementitious-like material and with a cap, encasement or otherfortification on the negative molding;

[0017]FIG. 3 is a section view through section line 2-2 of FIG. 2; and

[0018]FIG. 4 is the positive molding adhered to an edifice.

DESCRIPTION OF PREFERRED EMBODIMENT

[0019] Listed numerically below with reference to the drawings are termsused to describe features of this invention. These terms and numbersassigned to them designate the same features throughout thisdescription. 1. Positive molding 2. Ornamental molding portion 3.Adhesional portion 4. Edifice 5. Surfacing material 6. Negative molding7. Base portion 8. Cutting instrument 9. Ornamental cuttingconfiguration 10. Forming portion 11. Fill space 12. Fortification

[0020] Referring to the FIGS. 1-4, an ornamental molding includes apositive molding 1 made of solidified foam material having an ornamentalmolding portion 2 and an adhesional portion 3. The ornamental moldingportion 2 has a selected size and shape for ornamenting an edifice 4.

[0021] The adhesional portion 3 includes size and shape for adherence tothe edifice 4. As shown in FIG. 2, it can include predetermined porosityfor penetration of an adhesive and a surfacing material 5 havingpredetermined material strength selectively.

[0022] The ornamental molding portion 2 shown in FIG. 4 is coated withpredetermined cementitious-like material having a selected coatingshape.

[0023] The solidified foam material has predetermined lightness, ease ofshaping, rigidity, adherence and adhesive adherence. It also has timedurability for use as an ornamental component of the edifice 4predeterminedly.

[0024] The cementitious-like material has predetermined weatherresistance, impact resistance, biological resistance and thickness forthe use of the positive molding 1 as an ornamental component of theedifice 4 predeterminedly.

[0025] Optionally, the solidified foam material can include a compoundof styrene that can be Styrofoam®.

[0026] Optionally, the cementitious-like material can include apredeterminedly colored ornamental surface.

[0027] A method for manufacturing the ornamental molding starts withproviding the solidified foam material for making the positive molding 1and a material for making a negative molding 6 for receiving thepositive molding 1 as predetermined. Also at the start, thecementitious-like material is provided for being affixed to theornamental molding portion 2.

[0028] The ornamental molding portion 2 and the negative molding 6 arethen sized and shaped congruently. Sizing and shaping the adhesionalportion 3 of the positive molding 1 and a base portion can be done priorto or after congruent sizing and shaping of the ornamental moldingportion 2 and the negative molding 6. The positive molding 1 and thenegative molding 6 can then be structurally fortified selectively byappropriate binding, encasement, cap or other fortification 12 tocompensate for any inadequacy of material strength of the solidifiedfoam material during the manufacturing process. A forming portion 10 ofthe negative molding 6 is release-conditioned by application of arelease agent or other appropriate means of assuring ease of release ofthe cementitious-like material on the positive molding 1 after beingapplied and allowed to set predeterminedly. If a particular designimprint is desired on the ornamental molding portion 2, then a layer ofmaterial, such as silicone rubber, with a design on it can be adhered tothe forming portion of the negative mold 6 before applying a releaseagent.

[0029] The cementitious-like material is then positionally applied tothe ornamental molding portion 2 of the positive molding 1 with thecementitious-like material being placed intermediate the ornamentalmolding portion 2 of the positive molding 1 and the negative molding 6.The cementitious-like material is allowed to set and then the positivemolding 1 is removed from the negative molding 6.

[0030] The adhesional portion 3 of the positive molding 1 is thenattached to the edifice 4 by adhesive, nails, screws or other fasteners.

[0031] The sizing and shaping of the ornamental molding portion 2 of thepositive molding 1 and a forming portion 10 of the negative molding 6can include cutting them from a single piece of solidified foam materialwith a cutting instrument 8 for producing the ornamental molding portion2 on a first side and the forming portion 10 on a second side of apredetermined ornamental cutting configuration 9. The cutting instrument8 shown in FIG. 1 is representative of a heated wire, a heated rod, afluid stream or a laser beam.

[0032] A fill space 11 is bounded by a molding wall of the ornamentalmolding portion 2 on the first side of the ornamental cuttingconfiguration 9 and by a forming wall of the forming portion 10 that isoppositely disposed on the second side of the ornamental cuttingconfiguration 9 as shown in FIGS. 1 and 3.

[0033] The cutting instrument 8 can include a cutting thickness forleaving a predetermined distance of separation between the molding walland the forming wall for containing the cementitious-like material toform the ornamental molding portion 2 of the positive molding 1. Forthis, the cutting instrument 8 can include a cutting wire havingpredetermined heat and thickness for heat-disintegrating the solidifiedfoam material intermediate the molding wall and the forming wall bypassage of the cutting wire congruously with the ornamental cuttingconfiguration 9.

[0034] The cutting instrument 8 can include a cutting wire havingpredetermined heat and thickness for heat-disintegrating the solidifiedfoam material intermediate the molding wall and the forming wall bypassage of the cutting wire congruously with the cutting configuration10.

[0035] The cutting instrument 8 can include a resistance-heated rodhaving is predetermined heat and thickness for heat-disintegrating thesolidified foam material intermediate the molding wall and the formingwall by passage of the resistance-heated rod congruously with theornamental cutting configuration 9.

[0036] The cutting instrument 8 can include a fluid stream havingpredetermined mass, flow speed and thickness for fluid-disintegratingthe solidified foam material intermediate the molding wall and theforming wall by passage of the fluid stream congruously with theornamental cutting configuration 9.

[0037] The cutting instrument 8 can include a laser beam havingpredetermined dimensions for laser-disintegrating the solidified foammaterial intermediate the molding wall and the forming wall by passageof the laser beam congruously with the ornamental cutting configuration9.

[0038] The sizing and shaping of the ornamental molding portion 2 of thepositive molding 1 and the forming portion 10 of the negative molding 6can include structuring them separately from separate pieces of materialhaving the ornamental cutting configuration 9 being bounded by themolding wall of the ornamental molding portion 2 on the first side ofthe ornamental cutting configuration 9 and by a forming wall of theforming portion 10 that is oppositely disposed on the second side of theornamental cutting configuration 9.

[0039] The positionally applying of the cementitious-like material tothe ornamental molding portion 2 of the positive molding 1 can includeremoval of gaseous bubbles from the cementitious-like material. Theremoval of the gaseous bubbles can be by vibrating the positive molding1 and the negative molding 6 prior to allowing the cementitious-likematerial to set.

[0040] A new and useful ornamental molding and method of manufacturehaving been described, all such foreseeable modifications, adaptations,substitutions of equivalents, mathematical possibilities of combinationsof parts, pluralities of parts, applications and forms thereof asdescribed by the following claims and not precluded by prior art areincluded in this invention.

What is claimed is:
 1. An ornamental molding comprising; a positivemolding made of solidified foam material; the positive molding having anornamental molding portion and an adhesional portion; the ornamentalmolding portion having a selected ornamental size and shape forornamenting an edifice predeterminedly; the adhesional portion having aselected adhesional size and shape for adherence of the adhesionalportion of the positive molding to the edifice; the ornamental moldingportion being coated with predetermined cementitious-like materialhaving a selected coating shape; the solidified foam material havingpredetermined lightness, ease of shaping, rigidity, material adherenceand adhesive adherence; the solidified foam material that is coated withthe cementitious-like material having time durability for use as anornamental component of the edifice predeterminedly; and thecementitious-like material having predetermined weather resistance,impact resistance, biological resistance and thickness for the use ofthe positive molding as an ornamental component of the edificepredeterminedly.
 2. The ornamental molding of claim 1 wherein: thesolidified foam material includes a compound of styrene.
 3. Theornamental molding of claim 1 wherein: the solidified foam materialincludes polyurethane.
 4. The ornamental molding of claim 1 wherein: thecementitious-like material includes predeterminedly fine sand.
 5. Theornamental molding of claim 1 wherein: the cementitious-like materialincludes predeterminedly colored stone.
 6. The ornamental molding ofclaim 1 wherein: the cementitious-like material includes predeterminedlysized stone.
 7. The ornamental molding of claim 1 wherein: thecementitious-like material includes pieces of predeterminedly shapedstone.
 8. The ornamental molding of claim 1 wherein: thecementitious-like material includes predeterminedly sized, shaped andcolored stone substitute.
 9. The ornamental molding of claim 1 wherein:the cementitious-like material includes predeterminedly gypsum.
 10. Theornamental molding of claim 1 wherein: the cementitious-like materialincludes predeterminedly a polymer.
 11. The ornamental molding of claim1 wherein: the cementitious-like material includes a predeterminedlysmooth ornamental surface.
 12. The ornamental molding of claim 1wherein: the cementitious-like material includes a predeterminedlycolored ornamental surface.
 13. The ornamental molding of claim 1wherein: the cementitious-like material includes a predeterminedlyshaped ornamental surface.
 14. The ornamental molding of claim 1wherein: the adhesional portion of the positive molding includespredetermined porosity for penetration of an adhesive predeterminedly.15. The ornamental molding of claim 1 wherein: the adhesional portion ofthe positive molding includes a surfacing material having predeterminedmaterial strength.
 16. A method comprising the following steps formanufacturing the ornamental molding: providing the solidified foammaterial for making the positive molding predeterminedly; providingmaterial for making the negative molding for receiving the positivemolding predeterminedly; providing the cementitious-like material forbeing affixed to the ornamental portion of the positive moldingpredeterminedly; sizing and shaping the ornamental molding portion ofthe positive molding and a forming portion of the negative moldingcongruently; sizing and shaping the adhesional portion of the positivemolding and a base portion of the negative molding selectively;structurally fortifying the negative molding selectively;release-conditioning the forming portion of the negative molding;positionally applying the cementitious-like material to the ornamentalmolding portion of the positive molding with the cementitious-likematerial being placed intermediate the ornamental molding portion of thepositive molding and the forming portion of the negative molding;allowing the cementitious-like material to set on the positive molding;and removing the positive molding from the negative molding.
 17. Themethod of claim 16 and further comprising: adhering the adhesionalportion of the positive molding to the edifice.
 18. The method of claim16 wherein: the sizing and shaping of the ornamental molding portion ofthe positive molding and the forming portion of the negative moldinginclude cutting them from a single piece of solidified foam materialwith a cutting instrument for producing the ornamental molding portionon a first side and the forming portion on a second side of apredetermined ornamental cutting configuration; and the ornamentalcutting configuration being bounded by a molding wall of the ornamentalmolding portion on the first side of the ornamental cuttingconfiguration and by a forming wall of the forming portion that isoppositely disposed on the second side of the ornamental cuttingconfiguration.
 19. The method of claim 18 wherein: the cuttinginstrument includes a cutting thickness for leaving a predetermineddistance of separation between the molding wall and the forming wall forcontaining the cementitious-like material to form the ornamental moldingportion of the positive molding.
 20. The method of claim 19 wherein: thecutting instrument includes a cutting wire having predetermined heat andthickness for heat-disintegrating the solidified foam materialintermediate the molding wall and the forming wall by passage of thecutting wire congruously with the cutting configuration.
 21. The methodof claim 19 wherein: the cutting instrument includes a resistance-heatedrod having predetermined heat and thickness for heat-disintegrating thesolidified foam material intermediate the molding wall and the formingwall by passage of the resistance-heated rod congruously with thecutting configuration.
 22. The method of claim 19 wherein: the cuttinginstrument includes a fluid stream having predetermined mass, flow speedand thickness for fluid-disintegrating the solidified foam materialintermediate the molding wall and the forming wall by passage of thefluid stream congruously with the cutting configuration.
 23. The methodof claim 19 wherein: the cutting instrument includes a laser beam havingpredetermined dimensions for laser-disintegrating the solidified foammaterial intermediate the molding wall and the forming wall by passageof the laser beam congruously with the cutting configuration.
 24. Themethod of claim 16 wherein: the sizing and shaping of the ornamentalmolding portion of the positive molding and the forming portion of thenegative molding include structuring them separately from separatepieces of material having the ornamental cutting configuration beingbounded by the molding wall of the ornamental molding portion on thefirst side of the ornamental cutting configuration and by a forming wallof the forming portion that is oppositely disposed on the second side ofthe ornamental cutting configuration.
 25. The method of claim 16wherein: the positionally applying of the cementitious-like material tothe ornamental molding portion of the positive molding includes removalof gaseous bubbles from the cementitious-like material.
 26. The methodof claim 25 wherein: the removal of the gaseous bubbles includesvibrating the positive molding and the negative molding prior toallowing the cementitious-like material to set.
 27. The method of claim16 wherein sizing and shaping the ornamental molding portion of thepositive molding and a forming portion of the negative molding furthercomprises attaching a layer of material bearing a design imprint to theforming portion of the negative molding.
 28. The method of claim 27wherein the material with the design imprint includes a polymer.